Self-sustaining package of building panel units



W. A. LYNCH Dec. 10, 1968 SELF-SUSTAINING PACKAGE OF BUILDING PANELUNITS Filed Dec. 19, 1966 Sheet 1 Fig. 5 //V VF /V 701?.

W/L LIAM A. L V/VCI/ 2 Sheets- Dec. 10, 1968 w. A. LYNCH 3,415,367

SBLF-5U5TAINING PACKAGE OF BUILDING PANEL UNITS Filed Dec. 19, 1966 2Sheets-Sheet 2 W mm] Fig.7

M I/EA TO/a .56 WILL/4M 4. LV/VCH United States Patent 3,415,367SELF-SUSTAINING PACKAGE OF BUILDING PANEL UNITS William A. Lynch,Connersville, Ind., assignor to H. H.

Robertson Company, Pittsburgh, Pa., a corporation of Pennsylvania FiledDec. 19, 1966, Ser. No. 602,739 8 Claims. (Cl. 206-65) ABSTRACT OF THEDISCLOSURE A self-sustaining package of building panel units comprisingat least one group of panel units arranged in faceto-face relation andpresenting opposite side edges. A plurality of frames are spaced alongthe length of the group of panel units. The frames include upper andlower horizontal elements, and vertical elements. Compressible membersare compressed between the opposite side edges and the upper and lowerhorizontal elements of the frames. The panel units are therebyresiliently clamped in the aforesaid face-to-face relation. The framesare connected together solely by the group of panel units.

This invention relates to the art of packaging, and more particularly toa self-sustaining package of building panel units and method ofpackaging said panel units.

One of the major problems facing manufacturers is how to package waresfor shipment so that the wares arrive at their destination in anundamaged condition. Modern packaging techniques provide sturdy packageswhich, though expensive, oifer good protection for the wares beingshipped.

Manufacturers of building construction materials have long been plaguedwith the problem of packaging their products in a manner which iseconomical and which minimizes the chance of damaging the product.

Of special interest in this connection, are those construction materialsknown generically as panel units and known specifically as facing sheetsand liner sheets. These panel units are made from various gauge flatmetal sheets and are formed into various profiles. Modern roll-formingequipment has now made it possible to produce these panel units inlengths up to forty feet. Such long panel units present packagingproblems not only because of their length, but also because of theirnarrow width, their profiles and their decorative surface coating ortexture, if any. These panel units cannot, for example, be stacked oneon top of the other and then banded together. Such packaging distortsthe panel units and hinders their erection, and mars the decorativesurface coat or texture, thereby detracting from their intendedattractive appearance, as well as producing other undesirable defects.

Objects As an overall object, the present invention seeks to provide aself-sustaining package of panel units which avoids the problemsdescribed above.

Another object of the present invention is to provide means forpackaging panel units which is economical and which may be assembled ina rapid and easy manner.

Still another object of the present invention is to provide a novelpackage wherein the panel units are resiliently clamped withoutdistorting the same.

A further object of the present invention is to provide a novel packagewherein the panel units are maintained in spaced-apart, substantiallyparallel relation so as to avoid marring the decorative surface coatingor texture thereof.

Yet another object of the present invention is to provide means forpackaging panel units of various profiles.

Patented Dec. 10, 1968 A further object of the present invention is toprovide a method for bundling panel units into a self-sustainingpackage.

Statement of invention In accordance with the present invention, aselfsustaining package of building units is provided wherein the panelunits are resiliently clamped in a fixed position without distorting thepanel units. Basically, the present self-sustaining package of buildingpanel units comprises sets of upper and lower horizontal elements. Meansis provided for maintaining the upper and lower horizontal elements in afixed, vertically spaced-apart, substantially parallel relation. Atleast one group of panel units is positioned between all of the upperand lower horizontal elements. The panel units are arranged on edge infaceto-face relation and present upper and lower longitudinal side edgesadjacent to the upper and lower horizontal elements. Compressiblemembers are compressed between the upper and lower longitudinal sideedges and the upper and lower horizontal elements whereby the panelunits are resiliently clamped and maintained in the aforesaidface-to-face relation. The compressible members are preferably providedwith spaced-apart grooves which receive the side edges of the panelunits and maintain the same space from each other. Engagement ofadjacent panel units and marring of their surface which could resultfrom such engagement, is effectively prevented.

Further in accordance with the present invention, the means formaintaining the horizontal elements in the desired fixed, verticallyspaced-apart, substantially parallel relation comprises (1) verticalelements spanning between and engaging corresponding ends of the upperand lower horizontal elements and (2) means, preferably in the form of ametal strap under tension, surrounding the horizonal and verticalelements of each set for securing the same together as a unit-said meansalso serving to maintain the compressible elements in a compressedcondition.

The present self-sustaining package may also be used to package twogroups of panel units which are positioned one above the other and whichare arranged on edge in face-to-face relation. In this arrangement, thegroups of panel units present adjacent inner side edges between whichare compressed additional compressible members. To further rigidity thepresent package, intermediate horizontal elements are positioned betweenthe adjacent inner edges and, in this instance, the additionalcompressible members are compressed between the opposite faces of theintermediate horizontal element and the adjacent inner edges.

The present invention also provides a novel method of bundling panelunits into a self-sustaining package. In its broadest aspects, thepresent method comprises the steps of arranging at least one group ofpanel units on edge and in face-to-face, substantially parallel relationsuch that the panel units present upper and lower longitudinal sideedges; positioning sets of upper and lower horizontal elements adjacentto the upper and lower side edges, at spaced locations along the lengthof the panel units and in a fixed, vertically spaced-apart relation;compressing compressible members between the upper and lower side edgesand the upper and lower horizontal elements; and maintaining the upperand lower horizontal elements in the aforesaid fixed, vertically spacedrelation throughout the life of the self-sustaining package whereby thecompressible members are held in compressed condition and resilientlyclamp the panel units in the aforesaid face-to-face, substantiallyparallel relation.

The above and other objects and advantages of the present invention willbecome apparent from the following detailed description by reference tothe accompanying drawings, in which:

FIGURE 1 is an isometric view of the present selfsustaining packagecontaining two groups of panel units;

FIGS. 2A2F are views schematically illustrating the profile of typicalpanel units which may be packaged in accordance with the presentinvention;

FIG. 3 is an end view, in partially assembled form, of the presentself-sustaining package;

FIG. 4 is a fragmentary isometric view of a compressible member employedin the present self-sustaining package;

FIG. 5 is an end view, similar to FIG. 3, illustrating the positions ofthe various components of the present package after banding;

FIGS. 6 and '7 are fragmentary end views of a panel unit disposedbetween a pair of compressible members and illustrating certainprinciples of the present method; and

FIG. 8 is an end view, similar to FIG. 5, illustrating an alternativearrangement of the present self-sustaining package containing only onegroup of panel units.

General description Referring now to FIG. 1, there is illustrated aselfsustaining package 10 containing first and second groups of panelunits 12, 14. Spacer means 16 cushion and separate the first and secondgroups of panel units 12, 14. Associated with each of the spacer members16 and surrounding the first and second groups of panel units 12, 14 areframes 18 which rigidify the entire selfsustaining package 11) into thegenerally rectangular configuration. An end plate 20 extends across theends of the first and second groups of panel units 12, 14 and is securedto the end frames 18. The end plate 20 prevents the panel units 12, 14from sliding in a longitudinal direction relative to the package 10 andprevents the package 10 from parallelogramming or collapsing. A bandingstrap 22 surrounds each of the frames 18 and connects its componentsinto a rigid unit. As will be described, the banding straps 22 providecompressive forces acting on the horizontal components of the frames 18which result in a resilient clamping of the first and second groups ofpanel units 12, 14 to maintain the panel units in a predeterminedorientation one to the other.

The present self-sustaining package 10 may be employed to bundle panelunits having a great variety of profiles. Although not limited thereto,the panel units of the first and second groups 12, 14 may comprise oneor a mixture of the panel units 2434 whose profiles are illustrated inFIGS. 2A2F. The panel units 2434 have similar portions and differ onlyin their profiles. For example, the panel unit 24 of FIG. 2A, includes acentral web 36 terminating in longitudinal side edges 38, 40 whichinclude a male lip 42 and a female lip 44, respectively. For the purposeof the present invention, the panel unit 24 will be shown bundled in theself-sustaining package 10. It should be understood, however, that thepackage 10 may be employed to bundle any one or a mixture of the panelunits 24-34. Panel units having profiles other than those illustrated inFIGS. 2A2F, may also be bundled in the self-sustaining package 16.

Anrangement of panel units In accordance with the present packagingtechnique and as shown in FIGS. 1 and 3, the panel units are arrangedface-to-face and stand on edge in spaced-apart, substantially parallelrelation. The second group of panel units 14 is positioned above thefirst group of panel units 12, the overall arrangement being such thatthe first and second groups of panel units 12, 14 present adjacent innerside edges 46 and remote outer side edges 48. The inner side edges 46and the outer side edges 48 may consist of either of the side edges 38,40 of the panel units 2434 as will be discovered when comparing thepanel units 24 as arranged in FIG. 3 with the panel unit 24 illustratedin FIG. 2A.

Each of the panel units 2434 of FIGS. 2A2F has an outer or exposedsurface 49 which normally has a decorative finish or is provided with adecorative surface coating. The exposed surface must be protected so asto avoid damaging the decorative finish or decorative surface coating.As can be seen in FIG. 5, an end panel unit 24A of each set of panelunits 12, 14 is inverted such that its outer surface 49 faces inwardlytoward the adjacent panel unit 24. The remaining panel units 24 of eachset 12, 14, face the end panel unit 24A. Consequently, at each side ofthe package 10, only the inner surfaces of the panel units 24, 24A areexposed and the outer surfaces 49 of all panel units are protected.

Spacer means 16 Referring again to FIG. 3, the spacer means 16 comprisesan intermediate horizontal member 50 and first compressible members 52engaged with the upper and lower faces of the intermediate horizontalmember 50 and secured thereto, for example, by any suitable fastener oradhesives. The intermediate horizontal member 50 preferably comprises ascrap metal strip of from 12-14 gauge thickness. The spacer means 16separates the first and second groups of panel units and extendstransversely thereof with the first compressible members 52 engagedacross the inner side edges 46 of the panel units 24. The preferredconfiguration and material of construction of the compressible members52 will be hereinafter described in connection with FIG. 4.

Frames 1 8 Referring still to FIG. 3, the frame 18 comprises a set ofupper and lower horizontal frame elements 54, 56, each having a secondcompressible member 58 secured thereto and positioned to be engagedacross the outer side edges 48 of the panel units 24. Vertical frameelements 60 are provided on each side of the frame 18. In the preferredconstruction, a first L-shaped support 62 is formed by securing one ofthe vertical frame elements 60 to the lower horizontal frame element 56.Similarly, a second L-shaped support 64 is formed by securing the othervertical frame element 60 to the upper horizontal frame element 54.

It is to be understood, at this time, that in FIG. 3 the compressiblemembers 52, 58 are in an uncompressed condition. Accordingly, theoverall height of the frame 18, as illustrated in FIG. 3, is greaterthan the overall height of the frame 18, as illustrated in FIG. 5wherein the compressible members 52, 58 have been compressed. Also to benoted is the fact that the overall length of the vertical frame elements60 is less than, for example, the distance between the opposed innerfaces 66 of the h0rizontal frame elements 54, 56 when the compressiblemembers 52, 58 are in an uncompressed condition. This relation isillustrated in FIG. 3 by the space shown between the remote ends 68 ofthe vertical frame elements 60 and the inner face 66 adjacent thereto.This space has been exaggerated in FIG. 3 for the purpose of clearlyillustrating this initial position of the first and second L-shapedsupports 62, 64 and the uncompressed condition of the compressiblemembers 52, 58.

Compressible members The compressible members 52, 58 have identicalconfigurations and, as illustrated in FIG. 4, comprise a generallyrectangular body 70 having uniformly spaced, first coplanar surfaces 72,second coplanar surfaces 73 spaced below the surfaces 72 andintermediate grooves 74. An end recess 76 is provided at each end of thegenerally rectangular body 70. Projecting above the coplanar surfaces 72and positioned adjacent the intermediate grooves 74 are ribs 78. Withthis configuration, the intermediate grooves 74 and the end recesses 76are adapted to receive the male lips 42 of adjacent panel units.Furthermore, the coplanar surfaces 72 are positioned to be engaged byeither of the side edges 38, 40 of the panel units. In this connection,the ribs 78 serve to maintain adjacent panel units in spaced-apartrelation and therefore prevent contact between the adjacent panel units.

The compressible members 52, 58 are preferably formed from a materialwhich is relatively rigid and yet compressible. Such materials include avariety of foamable resin compositions of which the preferred materialis known as expanded polystyrene. Alternatively, the compressiblemembers 52, 58 could, instead, be formed from foamed polyurethane,foamed polyethylene, foamed phenolic resins, foamed urea-formaldehyderesins, and the like.

Assembly of frames Referring again to FIG. 3, because the compressiblemembers 52, 58 are in an uncompressed condition, the first and secondL-shaped supports 62, 64 are in a spacedapart relation. However, thefirst and second L-shaped supports 62, 64 will be forcibly moved towardeach other and united into the frame 18, as shown in FIG. 5. Duringforceful movement of the first and second L-shaped supports 62, 64, thecompressible members 52, 58 will be compressed such that the first andsecond groups of panel units 12, 14 are resiliently clamped between thecompressible members 52, 58 and relatively rigidly maintained in thedesired face-to-face, spaced-apart relation shown in FIG. 1.

It is preferred, in the present invention to employ the banding strap 22for securing the L-shaped supports 62, 64 together as a unit to form theframe 18. As is conventional, a connector 80 is provided which receivesthe ends of the strap 22. Use of conventional banding equipment, permitsthe strap 22 to be placed under sufiicient tension such that theL-shaped supports 62, 64 are forcibly displaced toward each other untilsuch time as the remote ends 68 of the vertical elements engage theopposed inner faces 66 of the horizontal frame elements 54, 56.

It is to be noted, at this time, that the vertical frame elements 60 andthe banding strap 22 cooperate to provide means for maintaining theupper and lower horizontal frame elements 54, 56 in a fixed, verticallyspacedapart, substantially parallel relation. This is necessary in orderthat the compressible members 52, 58 may be placed in a compressedcondition.

To better understand the manner in which the panel units are resilientlyclamped, reference is now directed to FIG. 6 wherein the horizontalelements 50 and 56 are shown separated by a distance indicated by thedimension line labeled L. Prior to tensioning the banding strap 22, thepanel unit 24 has its opposite side edges 38, 40 engaged with thesurfaces 72, 73 of the compressible members 52, 58. The male lip 42,herein provided with a U- gasket 88, is engaged in a bottom surface 90of the groove 74. The panel units 24 are maintained in thison-edgeposition by engagement of the horizontal elements 50 with theL-shaped supports 62, 64 as illustrated in FIG. 3.

After the banding strap 22 has been placed under tension, the horizontalelements 50, 56 will be forcibly displaced toward each other and are nowseparated, as shown in FIG. 7, by a distance indicated at M which isless than the spacing L. The compressible forces acting on thehorizontal elements 50, 56, provided by tensioning the banding strap 22,are schematically shown in FIG. 7 by groups of force lines labeled F. Atthis time, those regions of the compressible members 52, 58 which areengaged by the adjacent inner side edges 46 and the remote outer sideedges 48 are compressed, that is, their thickness is reduced. The panelunits 24 of the first and second groups of panel units 12, 14 are thusresiliently clamped between the compressible members 52, 58 and therebymaintained in the desired face-to-face spacedapart substantiallyparallel relation, best shown in FIG. 5.

It is to be noted that the panel units 24 are resiliently clampedwithout being distorted. Furthermore, inasmuch as the panel units 24 aremaintained in spaced-apart relation, water cannot be trapped between thepanels and, hence, corrosion of the panel units attributed to trappedwater is prevented.

To complete the present self-sustaining package 10, the end plates 20(FIG. 1) are applied to the end frames 18. The end plates 20 extendacross the ends of the panel units 24 and prevent the same from slidinglongitudinally of the package 10.

Referring again to FIG. 1, the intermediate frames 18 may be providedwith grooves 82 positioned below the horizontal frame elements 54. Thegrooves 82 are formed by cutting out a central portion of thecompressible members 58. The grooves 82 are aligned and receive ahoisting strap, illustrated in dotted outline at 84, which is attachedto a cable, illustrated in dotted outline at 86, for the purpose oflowering or raising the self-sustaining package 10.

Although it is preferred from an economic standpoint to package twogroups of panel units in one package, it is sometimes necessary topackage only one group of panel units. In this connection, reference ismade to FIG. 8 wherein there is illustrated a self-sustaining package10' containing one group of panel units 12.

The package 10' includes upper and lower horizontal elements 54, 56 eachhaving a compressible member 58 secured thereto. Vertical elements 611)are engaged between the corresponding ends of the horizontal elements54. The horizontal and vertical elements 54, 56, 60 are secured togetherto form a frame 18' by a banding strap 22. The self-sustaining package10' is similar in construction to and is assembled in the same .manneras the selfsustaining package 10. In this respect, end plates, not shownhere, would be secured to the end ones of the frames 18'.

Summary From the foregoing detailed description, it should be readilyapparent that the present invention provides a selfsustaining package ofbuilding panel units which is economical and which may be assembled in arapid and easy manner. The present self-sustaining package incorporatescompressible members which (1) resiliently but firmly clamp the panelunits without distorting the same; and (2) maintains the panel units inspaced-apart relation so as to avoid contact between panel units and thedamage caused by such contact; and so as to avoid the accumulation oftrapped water and the corrosion caused by the water. The presentself-sustaining package may be raised and lowered in a manner whichavoids damage to the panel units. All-in-all, the presentself-sustaining package avoids substantially all of the problemsencountered in prior art packaging techniques. Finally, the presentinvention provides a novel method of bundling panel units into aself-sustaining package.

I claim as my invention:

1. A self-sustaining package of building panel units, comprising:

a plurality of spaced-apart frames, each of said frames comprising upperand lower horizontal elements and vertical elements maintaining theupper and lower horizontal elements in fixed, vertically spaced,generally parallel relation;

at least one group of panel units residing between the upper and lowerhorizontal elements and between the vertical elements of said pluralityof spaced-apart frames, said panel units being arranged in a face-tofacerelation and having opposite side edges adjacent to the upper and lowerhorizontal elements of said frames;

means for securing the upper and lower horizontal elements of each ofsaid frames together as a unit; and

compressible members compressed between said opposite side edges and theupper and lower horizontal elements of said frames, said group of panelunits being resiliently clamped in said face-to-face relation; saidplurality of spaced-apart frames being connected together solely by saidgroup of panel units.

2. The self-sustaining package defined in claim 1 wherein saidcompressible members have spaced grooves which receive said side edgesand maintain said panel units in spaced-apart relation.

3. The self-sustaining package defined in claim 1 wherein saidcompressible members are formed from foamed polystyrene.

4. The self-sustaining package defined in claim 1 wherein one end ofsaid vertical elements is secured to one of said upper and lowerhorizontal elements.

5. The self-sustaining package defined in claim 1 wherein said means forsecuring comprises:

a tensioned metal strap surrounding the upper and lower horizontalelements and the vertical elements of each of said frames. 6. Theself-sustaining package defined in claim 1 Wherein:

one of said frames including compressible members is positioned at eachend of said group of panel units, and including end plates spanningacross the ends of said panel units and secured to said frames.

7. A self-sustaining package of building panel units, comprising:

sets of upper and lower horizontal elements;

means for maintaining the upper and lower horizontal elements of saidsets in fixed, vertically spaced, generally parallel relation;

two groups of panel units positioned one above the other and residingbetween the upper and lower horizontal elements of said sets, the panelunits of each of said groups being arranged in a face-to-face relation,one of said groups presenting opposite side edges adjacent to the saidupper horizontal elements and the other of said groups presentingopposite side edges adjacent to the said lower horizontal elements, thesaid two groups presenting inner side edges which are adjacent to eachother;

compressible members compressed between said opposite side edges and theupper and lower horizontal elements of said sets; and

additional compressible members compressed between the said inner sideedges of said groups of panel units;

said panel units being resiliently clamped in said faceto-face relation.

8. The self-sustaining package defined in claim 7 wherein saidadditional compressible members are positioned directly beneath saidupper horizontal elements.

References Cited UNITED STATES PATENTS 2,730,259 1/1956 Frick 206652,990,951 7/1961 Fallert 20665 3,307,691 3/ 1967 Vallebona 206623,339,722 9/1967 Van Antwerpen 20662 WILLIAM T. DIXSON, JR., PrimaryExaminer.

